Platypus Owner Manual.pub

Platypus Owners Manual
Level and Pressure Measurement
Platypus Models
Standard
Plasc
Rigid
Plug
Level Sck
Common Accessories
Vent Box
PL-TERM-SG/TX-E
Australia
Phone: 1800 811 818
Email: [email protected]
Web: www.ecefast.com.au
Rev: June 2012
DIN Mount Transmi'er
PL-TX-DIN
2-Wire Lightning
Protecon
PR Electronics
DIN Rail Mount
Transmi'ers
New Zealand
Phone: 0800 323 327
Email: [email protected]
Web: www.ecefast.co.nz
1
Platypus Installation Guide
Platypus Mechanical Considerations
The PLATYPUS uses a gauge (referenced to atmospheric pressure) type sensor. This requires that the cable end
be terminated so that it is open to the atmosphere but protected from moisture ingress. All the PLATYPUS
cabling op,ons (including the Standard Nylon Tubing, 6 core vented cable and Military Plug) provide this atmospheric reference for the sensor. When the unit is installed in loca,ons such as pumping sta,ons or tanks
inside buildings this is generally easy to achieve. For installa,ons in exposed loca,ons such as reservoirs and
loca,ons where there is a high ambient humidity it is mandatory to terminate the cable in a enclosure such as
the PL-TERM-SG/TX-E. This provides an entry cable gland for the PLATYPUS cable and another gland for system
cabling to exit. There is also a vent that allows atmospheric reference to be maintained but eliminates water ingress, together with silica gel desiccant inside the enclosure to absorb any moisture that does penetrate.
The standard nylon tubing type cable that is supplied with the PLATYPUS comes with a stainless steel support
wire that should be used to mechanically support the PLATYPUS in posi,on. Where cable length is less than 5m
and the PLATYPUS is not mounted in a posi,on where it is subject to turbulence it is permissible to dispense
with the support wire and support the PLATYPUS using the nylon tubing. UNDER NO CIRCUMSTANCES SHOULD
THE INSTRUMENT CABLE BE DRAWN THROUGH THE TUBING, OR THE 6 CORE VENTED CABLE BE USED TO SUPPORT THE UNIT!
Manifold mounted units should be protected from pressure spikes such as water hammers, and from freezing of
the liquid in the pipe (both these events will damage the diaphragm of the sensor). Another point to note is that
any air trapped on installa,on should be bled off.
The diaphragm of the sensor is extremely delicate and should not be pressed with any object (fingers and
screwdrivers included) as these will cause permanent damage to the sensor. We have found that a large
propor,on of PLATYPUS sensors sent for repair have no faults other than a dented diaphragm suffered during a
"test". For trouble shoo,ng procedures please refer to that sec,on of this manual. A pressure spike that can
damage the sensor can also be generated by dropping the sensor into a tank or reservoir, the sensor should be
lowered into posi,on.
All the components of the PLATYPUS body are constructed from 316 stainless steel and are highly resistant to
corrosion. Concentra,ons of chlorine can cause corrosion of stainless steel so care must also be taken in not
loca,ng the unit close to chlorine dosing points. FOR SALINE WATER from bores or seawater use the PLASTIC
VERSION OF PLATYPUS.
Platypus Electrical Considerations
The PLATYPUS uses a strain gauge type pressure sensor that is supplied either with 4 wire strain gauge output
or fiHed with an internal 4-20mA loop powered transmiHer, the PLATYPUS-TX.
4 Wire Output (PLATYPUS-SG, PLATYPUS-LP)
The 4 wire strain gauge output version can be used with either an external strain gauge transmiHer such as the
PL-TX-DIN which provides a loop powered 4-20mA output, or with a strain gauge input indicator/alarm unit. The
PLATYPUS-LP Lightning Protected strain gauge version has the LP PCB fiHed inside the housing and this is transparent to any transmiHer or indicator. Internal lightning protec,on is only available with the strain gauge version
of the PLATYPUS.
Rev: June 2012
2
These SG units are supplied calibrated with their transmiHer or indicator but the calibra,on can be altered in
the field if required. (see field calibra,on with PL-TX-DIN page 5)
Units that are to be installed in lightning prone areas should also have some form of surge protec,on on the 420mA loop. The PL-TX-DIN transmiHer includes a loop surge protector but if this transmiHer is not used then a device such as the PLATYPUS-ELP should be used. On long cable runs loop surge protec,on should be used on
both ends of the loop.
On LP versions, the stainless steel support wire also forms the ground connec,on for the LP PCB and MUST be
connected, with a maximum resistance of 1 ohm to ground, for the lightning protec,on to be effec,ve.
Internal 4-20ma Transmi'er (PLATYPUS-TX)
The PLATYPUS-TX has a 4-20mA loop powered transmiHer fiHed internally. It is recommended for sensors where
the cable length exceeds 20m or where using an external transmiHer is unsuitable. This output interfaces directly
with telemetry and process control systems. Indicator/Alarm units such as the PR-5714 can power and monitor
the output of the sensor without the need for a separate DC power supply.
The calibra,on depth must be specified at the ,me of order and this cannot be changed in the field. If the calibra,on needs to be changed the unit must be returned to ECEFast – see “Repair of Platypus” sec,on for instruc,ons
on sending units to ECE.
If the unit is to be installed in a lightning prone area loop surge protec,on should be installed as described above,
as close as prac,cal to the sensor.
The internal transmiHer is reverse polarity protected.
Use of an external SCALING power supply such as PR-4114 allows high level galvanic isola,on and enables calibra,on of the 4-20mA output - external to the PLATYPUS-TX.
Colour Code of Cable Connecon
• Posi,ve – Red and Black Wires twisted
• Nega,ve – Green and white wires twisted
These pairs are separately screened with a common drain wire – earth this at remote end only.
Platypus Electrical Considerations
Mechanical:
⇒
Terminate cable in a suitable enclosure such as the PL-TERM-SG/TX-E, linked to atmospheric pressure
but protected from water/humidity ingress.
⇒
For submersible versions use stainless steel support wire to hold sensor.
⇒
If manifold moun,ng protect against pressure spikes (e.g. water hammer) and water freezing in pipes.
⇒
DO NOT TOUCH DIAPHRAGM!
⇒
Lower the PLATYPUS into posi,on, DO NOT DROP IN.
⇒
Do not mount next to chlorine dosing points or SS versions in saline waters
Electrical:
⇒
See wiring diagrams for electrical connec,ons.
⇒
The cable should be located away from any power wiring or electrically noisy areas.
⇒
The cable shielding should be connected to a good earth.
Rev: June 2012
3
⇒
⇒
⇒
Sites prone to lightning strikes should use the lightning protected sensors and a surge protector at each
end of the 4-20mA loop to the transmiHer such as the PLATYPUS-ELP. The PL-TX-DIN includes an integral 4- 20mA surge protector that requires the male spade connector on the side of the unit to be connected to a good earth.
Check the output of the sensor (if TX version) or transmiHer (if SG or LP version) immediately aLer installa,on.
Make sure the signal wires are isolated from the body of the platypus
Configuration Description Build Number
All PLATYPUS sensors have a build number engraved in the body that describes the physical and electrical configura,on of the unit.
Platypus units are idenfied by a small number of physical variables including the type, the cable length, the calibrated depth and the accessories. If in doubt request a Platypus configuraon sheet which is available for Standard [SG, TX, and LP], Plug, Plasc, and Rigid versions.
Field Calibraon (PLATYPUS-SG and PLATYPUS-LP) with PL-TX-DIN Transmi'er
1. Se<ng the Dip Switches On The PL-TX-DIN For Gross Range Change Selecon
The output of the pressure sensor used in the PLATYPUS is nominally 100mV for full scale output. The full scales
ranges of the sensors used are:
•
1 bar (10mWG) for sensors up to 10mWG
•
2 bar (20mWG) for sensors between 10m-20mWG
•
7 bar (70mWG) for sensors between 20m-70mWG
To calculate the mV output of a sensor at a specific depth: mV
Output = 100mV x (Depth)/(Full Scale Depth of sensor). Then simply select the range DIP switch on the PL-TX-DIN that this output falls into.
E.g. A PLATYPUS sensor was supplied by ECEFast with a PL-TX--DIN calibrated to 8m WG. It is now desired to use the unit in a water tank with a
maximum 4m depth.
The unit was originally scaled to under 10m WG so has a 1 bar sensor
installed so the Full Scale Depth of the sensor is 10m. The mV output at 4m = 100mV x (4m)/(10m) = 40 mV. This falls into the range covered by DIP switch No:6 on the PL-TX--DIN. Set this switch to the ON
posi,on, all other switches OFF.
2. Adjusng the Zero and Span Pots on the PL-TX-DIN
•
Connect the Sensor to the PL-TX-DIN transmiHer and put a mA meter in series
with the output.
•
With the sensor out of the tank adjust the Zero pot so that the output of the
PL-TX-DIN is 4mA.
•
Lower the sensor into the tank to a known depth and adjust the span so that
the output is the correct propor,on of the full scale range required. mA Output = 4mA + (Known Depth)/(max Depth) x 16
E.g. The PLATYPUS sensor is lowered gently to a known depth of 3m and the max
depth is 4m
MA Output = 4mA + (3m/4m) x 16 = 16mA
The zero and span adjustment can be repeated if required.
On PL-TX-DIN transmiHers used with the PLATYPUS-LP model, the ground pin MUST be connected with a maximum
resistance of 1 ohm to ground, for the lightning protec,on to be effec,ve.
Rev: June 2012
4
PL-TX-DIN Transmi'er
1. Se<ng the Dip Switches On The PL-TX-DIN For Gross Range Change Selecon
The output of the pressure sensor used in the PLATYPUS is nominally 100mV for full scale output.
The full scales ranges of the sensors used are:
•
1 bar (10mWG) for sensors up to 10mWG
•
2 bar (20mWG) for sensors between 10m-20mWG
•
7 bar (70mWG) for sensors between 20m-70mWG
To calculate the mV output of a sensor at a specific depth: mV Output =
100mV x (Depth)/(Full Scale Depth of sensor). Then simply select the range DIP switch
on the PL-TX-DIN that this output falls into. E.g.: A PLATYPUS sensor was supplied by
ECEFast with a PL-TX--DIN calibrated to 8m WG. It is now desired to use the unit in a
water tank with a maximum 4m depth.
The unit was originally scaled to under 10m WG so has a 1 bar sensor installed so
the Full Scale Depth of the sensor is 10m. The mV output at 4m = 100mV x (4m)/
(10m) = 40 mV. This falls into the range covered by DIP switch No:6 on the PL-TX--DIN. Set this switch to the ON
posi,on, all other switches OFF.
i 2. Adjusng the Zero and Span Pots on the PL-TX-DIN
i.
Connect the Sensor to the PL-TX-DIN transmiHer and put a mA meter in series with the output.
ii.
With the sensor out of the tank adjust the Zero pot so that the output of the PL-TX-DIN is 4mA.
iii.
Lower the sensor into the tank to a known depth and adjust the span so that the output is the correct
propor,on of the full scale range required. mA Output = 4mA + (Known Depth)/(max Depth) x 16 E.g.
The PLATYPUS sensor is lowered gently to a known depth of 3m and the max depth is 4m, therefore, the
MA Output = 4mA + (3m/4m) x 16 = 16mA
iv.
The zero and span adjustment can be repeated if required.
v.
On PL-TX-DIN transmiHers used with the PLATYPUS-LP model, the ground pin MUST be connected with a
maximum resistance of 1 ohm to ground, for the lightning protec,on to be effec,ve.
Troubleshoong
At the first sign of a problem with a PLATYPUS sensor it should be removed from service immediately. Leaving it
connected and submerged will inevitably increase the cost of the repair.
1.
2.
3.
By far the most common cause of sensor failure is moisture in the cable. A simple test for this is to measure the resistance between any of the output wires and the body of the PLATYPUS with a mul, meter
(Using a Megger WILL damage the sensor) this should be very high, nearing infinity. If the resistance is less
than this then it is certain that there has been moisture penetra,on down the cable. The unit will need to
be returned to ECEFast with its transmiHer (if a strain gauge SG or lightning protec,on LP version) for repair.
For strain gauge versions the bridge resistance can also be measured. Remove the 4 wires from the transmiHer (or indicator) and measure the resistance between the Black and White wires (excita,on side of
bridge), this should be about 3-4k Ohms. Now measure the resistance between the Red and Green wires
(output side of bridge), this should be about 5k Ohms. These readings vary from sensor to sensor but
use these values as a guide.
If the above readings proved to be OK then it is almost certain that the sensor is in working order and the
problem lies elsewhere. Things to check are:
•
All connec,ons to transmiHer.
•
Power supply
•
Measure current flowing in 4-20mA loop. This should be 4mA with the sensor connected but not
installed. The tests and checks above will enable you to iden,fy the component at fault. If the
PLATYPUS or its transmiHer needs to be returned to ECEFast for repair the matching sensor + transmiHer pair should be returned together where possible.
Rev: June 2012
5
Specificaons
PLATYPUS-LP Internal Lightning Protecon
•
Sensing element: Strain gauge type pressure sensor.
•
Ranges Available 0.35, 1, 2, 7, 17 bar
•
Accuracy 0.2% FSO
•
FSO at 1mA excita,on 100mV nominal (min 70, max 130)
•
Over-pressure 2 x sensor ra,ng
•
Non-sacrificial mul,stage lightning protec,on tested to IEC 1000-4-5
•
Housing dimensions 32mmØ x 140mm
•
Housing and diaphragm material 316 SS
•
O-Ring material Nitrile (Viton available on request)
•
Process connec,on 1/2" BSP, cable connec,on 1/4" BSP or sealed mul,-pin socket
•
Maximum immersion depth 100m water
PLATYPUS-TX Internal Transmi'er
•
Supply Voltage 10-40VDC
•
Output 4-20mA loop powered
•
Input range 4mV-115mV
•
Gross range changes link selectable. Zero and Span pots 20% adjustment.
•
Accuracy 0.2% FSO
•
Opera,ng temperature range 0-70 °C
PL-TX-DIN External Transmi'er
Supply Voltage 8.5-40VDC
Output 4-20mA loop powered with integral surge protec,on tested to AS1768 Category B
Accuracy <0.3% FSO
Opera,ng temperature range 0-70 °C
Input range 5-150mV dip switch selectable
•
•
•
•
•
Standard Cable
4 core instrument wire drawn down Ø8mm rigid nylon tube with SS support wire. 10m long.
Cable Opons
•
Rigid nylon tube with/without support wire to max length of 50m
•
6 core polypropylene vented cable with/without support wire to max length of 500m.
•
Pipe mount (PLATYPUS-TXP (plug) and –TXC (cable) versions) come with 10m vented polypropylene cable.
Standard Vented Terminal Box (PL-TERM-SG/TX-E )
This robust terminal box is designed to match the Platypus range of
sensors and fulfills the func,on of protec,ng the top of the cable
from water entry and providing convenient termina,on of the cables,
as well as ven,ng the sensor to atmosphere effec,vely.
•
IP65 enclosure
•
Atmospheric reference
•
DIN rail terminals
•
Contains desiccant to protect sensor
•
FiHed cable glands
Rev: June 2012
6
Platypus Level Sck Installaon Guide
‘Levels,ck’ is a low-cost con,nuous transmiHer for level measurement in highly contaminated liquids and slurries,
including raw sewerage. All weHed parts are non-metallic, and resist organic and many inorganic chemicals at low
temperatures. It is shipped in a standard air satchel and assembled on-site with simple tools and familiar
processes.
Level Sck Assembly Instrucons
1. The following items may be procured from most leading hardware or plumbing stores:
•
A length of 32mm PVC pressure pipe to suit your applica,on, and
•
Priming fluid and PVC adhesive to suit PVC-U pipes and fiXngs. This is available in 125ml boHles.
•
PVC pressure pipe is available in 3 classes, [PN] based on pressure ra,ngs: 9, 12 and 18.
•
For short Levels,cks, to say 1-2 metres, Class 9 is sufficient, for Levels,cks of 4 metres and above, use Class
18 [PN18]. See Item 10 for further informa,on.
2.
3.
4.
5.
6.
7.
8.
9.
10.
Feed the cable of the sensor assembly loosely up through the length of PVC pressure pipe, then through end
cap and gland. Leave the gland loose enough for cable to slide through freely.
Apply PVC primer to both ends of pressure pipe, as well as to inside ma,ng surfaces of adaptor flange of
sensor assembly and the inside of the end cap /gland assembly, to prepare the surface for assembly with PVC
cement. Always refer to manufactures instruc,ons prior to using either the primer or adhesive.
Apply PVC pipe adhesive to the end of the pressure pipe, and the inside of the adaptor flange of the sensor
assembly and push firmly together. Remove excess adhesive. See Diagram 1.
Repeat the process at 4. with the top end of the pressure pipe, and top cap. See Diagram 2.
Leave some cable slack in the PVC pressure pipe before ,ghtening the cable gland and ensure cable entry has
waterproof seal. Do not pull on the cable to test if gland is ,ght enough as this may damage internal wiring
connec,on. Gland ,ghtness and sealing of cable can be easily tested by trying to push the cable through the
gland.
Allow appropriate ,me for adhesive to cure as per manufacturer’s direc,ons for use.
AHach or fix PL-LEVELSTICK assembly and connect wiring to suit your applica,on.
Standard PL-LEVELSTICK is fiHed with a 0 to 1 BAR ( 10.2mWG ) sensor and has 4-20mA output. Power supply
requirement: 8-30Vd.c. Connec,ons: Red = posi,ve, Blue = nega,ve.
In many cases, the sensor will be mounted in a flange or compression fiXng which, in turn, will be mounted
in the top of a tank and it will be unsupported i.e. can,levered. When this is done, the longer the probe, the
more prone it will be to lateral movement at the ,p due to applied forces from the liquid, including the force
of buoyancy. This is why, in recommending the PVC tube, Item 1, we suggest a heavier wall for longer
probes. An alterna,ve, which would allow using the lighter tube, is to provide support at the ,p, or along the
probe, to prevent movement sideways. Saddles or "ring" form brackets are ideal and can be designed to
allow ready removal of the sensor.
Diagram 1
Diagram 1
Platypus Repair
‘To return a PLATYPUS product to ECE for repair or warranty claim, please phone (toll free) on 1800 180 977 to ask
for a RRF (Return Request Form) or a Warranty Claim Form. This form will provide all the details you need to send
the units to us, and by comple,ng the form fully, ensures we can service your needs as quickly as possible.
Rev: June 2012
7
Platypus Warranty
The Platypus units are covered by warranty, as per ECE’s Standard Terms and Condi,ons of Sales. A current version
can be provided upon request or from our website. However, it is worth no,ng that special condi,ons apply for
pressure sensors and transducers. An excerpt from the warranty sec,on is reproduced here:
“Pressure transducers will be replaced only if it is clearly shown to fail due to a defect of manufacture. No warranty
will be applicable to units subject to overpressure demonstrated by open circuit bridge, plas,c deforma,on of the
sensor or excessive zero shiL.”
Rev: June 2012
8